Cut the top to length and position the partially assembled case on the underside of the top. Make sure the case is centered on the top and flush at the back edge. Add the screws and the top is attached. To finish construction of the case, install the drawer rail and the lower nailing rail.
Place the project on its top with the front facing you and fit the mouldings against the project. Make the first set of moulding cuts at the miter saw, leaving the side moulding extra long. Match those cuts to form the leftfront corner. Hold the front moulding tight to the case and move to the next corner of the project to find the cut line.
Position the side mouldings and mark a line at the back edge of the shelf. The 90º cut is made with the piece flat at the miter saw. Add glue to the miters and attach the mouldings with 3d nails. (For additional information on fitting mouldings, download the free manual).
To properly fit an inset drawer, the front should be about 1/8″ smaller than the opening – 1/16″ on either edge. Measure the opening from side to side and subtract 1/8″. Then subtract the thickness of the two sides (1 1/2″) to arrive at the cut length of the front and back of the drawer box. Drill two pocket-screw holes at each end of the these pieces.
Next, cut the drawer sides to size and attach the front to the sides with pocket screws. Careful alignment of the joint makes attaching the drawer face stronger. Complete the drawer box by installing the back piece.
Measure for the drawer face, including the thickness of the plywood bottom. Cut the plywood a little oversized, then add glue to the front rail of the drawer box, position the box onto the drawer face and add clamps as shown below.
Once the glue is dry trim the face with your plane, making the box and face flush on all sides. Finally, install store-bought wooden knobs.
To complete the shelf, knock off any sharp edges with #100-grit sandpaper, apply two coats of your favorite paint color, then cut and install the plywood back with 3d finish nails. Your Shaker-inspired shelf is ready to hang. PW
Questions or comments? You can reach Glen at 513-531-2690 ext. 1293 or firstname.lastname@example.org.